Sterling GP User Manual
GP Series
Portable Chillers
Part Number: 882.93092.00
Bulletin Number: SC2-620
Effective: 5/1/2009
Write Down Your Serial Numbers Here For Future Reference:
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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
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© Copyright 2009
All rights reserved.
Shipping Information
Unpacking and Inspection
You should inspect your equipment for possible shipping damage. Thoroughly check the
equipment for any damage that might have occurred in transit, such as broken or loose wiring
and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. In addition to the
equipment itself, you should have:
Bill of lading
Packing list
Operating and Installation packet
Electrical schematic and panel layout drawings
Component instruction manuals (if applicable)
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the parts and service department
immediately at (262) 641-8610. Have the order number and item number available.
Hold the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
GP Series Portable Chillers ii
Table of Contents
CHAPTER 1: SAFETY................................................................5
1-1 How to Use This Manual.............................................................................................5
Safety Symbols Used in this Manual.....................................................................5
1-2 Warnings and Precautions..........................................................................................6
1-3 Responsibility..............................................................................................................6
CHAPTER 2: FUNCTIONAL DESCRIPTION.............................7
2-1 Models Covered in This Manual..................................................................................7
2-2 General Description.....................................................................................................7
Chilled Water Circuit..............................................................................................7
Refrigeration Circuit...............................................................................................7
2-3 Standard Features.......................................................................................................8
Mechanical Features.............................................................................................8
Electrical Features.................................................................................................8
Refrigeration Features...........................................................................................9
Controller Features................................................................................................9
Other Features ......................................................................................................9
2-4 Safety Devices and Interlocks.....................................................................................9
Crankcase Heater .................................................................................................9
High Pressure Cutout..........................................................................................10
Low Pressure Cutout (no switch but done through the transducer) ....................10
Flow Switch .........................................................................................................10
Remote Start/Stop Interlock ................................................................................10
2-5 Optional Features......................................................................................................10
CHAPTER 3: INSTALLATION..................................................13
3-1 Uncrating...................................................................................................................13
3-2 Electrical Connections...............................................................................................13
3-3 Process Water Connections.......................................................................................14
3-4 Bypass Valve Considerations....................................................................................14
3-5 Galvanic Corrosion Considerations...........................................................................14
3-6 Water Treatment Considerations ..............................................................................14
3-7 Condenser Considerations........................................................................................15
Water-Cooled Chiller Condensers.......................................................................15
Air-Cooled Chiller Condensers............................................................................15
3-8 Checking Motor Direction..........................................................................................16
Three-Phase Compressors .................................................................................16
Water Pumps.......................................................................................................16
Condenser Fan....................................................................................................16
3-9 Water Reservoir ........................................................................................................17
3-10 Automatic Water Make-Up Option.............................................................................19
3-11 Initial Start-Up............................................................................................................19
3-12 Finishing Setup: Setting Up Passwords....................................................................19
CHAPTER 4: OPERATION.......................................................22
GP Series Portable Chillers iii
Panel Buttons, Indicator Lights, and Switches..........................................................22
4-1
Microprocessor Controller ...................................................................................22
4-2 Initial Start-up............................................................................................................23
4-3 Status Screens..........................................................................................................25
4-4 Access Levels ...........................................................................................................26
4-5 Controller Setpoints...................................................................................................28
4-6 Alarms.......................................................................................................................30
4-7 Optional Communications.........................................................................................30
CHAPTER 5: MAINTENANCE .................................................32
5-1 Lubrication.................................................................................................................32
5-2 Filter Cleaning...........................................................................................................32
5-3 Maintaining the Condenser .......................................................................................32
Air- and Remote Air-Cooled Chillers ...................................................................32
Water-Cooled Chillers .........................................................................................32
5-4 Maintaining the Evaporator .......................................................................................33
5-5 Evaporator Process Piping Y-Strainer.......................................................................33
5-6 Preventative Maintenance Service............................................................................33
CHAPTER 6: TROUBLESHOOTING .......................................34
CHAPTER 7: APPENDIX..........................................................36
7-1 Returned Material Policy...........................................................................................36
Credit Returns .....................................................................................................36
7-2 Technical Assistance.................................................................................................37
Parts Department ................................................................................................37
Service Department.............................................................................................37
Sales Department................................................................................................37
Contract Department...........................................................................................37
7-3 Specifications............................................................................................................38
Air-Cooled Portable Chillers................................................................................38
Water-Cooled Portable Chillers...........................................................................40
7-4 Pump Curves, Flow, and Pressure Considerations...................................................42
60 Hertz Pump Curves........................................................................................42
7-5 Electrical Schematic..................................................................................................44
GP Series Portable Chillers iv
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
equipment. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and optional
features. Additional sections within the manual provide instructions for installation, preoperational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the equipment. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the equipment.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the equipment safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your equipment provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, and parts lists. A
spare parts list with part numbers specific to your machine is provided with your shipping
paperwork package. Refer to this section for a listing of spare parts for purchase. Have your
serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING indicates a potentially hazardous situation or practice which, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice which, if not avoided,
may result in minor or moderate injury or in property damage.
GP Series Portable Chillers Chapter 1: Safety 5 of 44
1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
9 Follow all SAFETY CODES.
9 Wear SAFETY GLASSES and WORK GLOVES.
9 Disconnect and/or lock out power before servicing or maintaining the equipment.
9 Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
9 Operate this equipment within design specifications.
9 OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
9 Make sure the equipment and components are properly GROUNDED before you
switch on power.
9 When welding or brazing in or around this equipment, make sure
VENTILATION is ADEQUATE. PROTECT adjacent materials from flame or
sparks by shielding with sheet metal. An approved FIRE EXTINGUISHER
should be close at hand and ready for use if needed.
9 Refrigeration systems can develop refrigerant pressures in excess of 500 psi
(3,447.5 kPa/ 34.47 bars). DO NOT CUT INTO THE REFRIGERATION
SYSTEM. This must be performed by a qualified service technician only.
9 Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
9 Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
GP Series Portable Chillers Chapter 1: Safety 6 of 44
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for air-, water-and
remote air-cooled portable chillers. Model numbers are listed on the serial tag. Make sure you
know the model and serial number of your equipment before contacting the manufacturer for
parts or service.
Our portable chiller models are designated by approximate compressor horsepower (5,7 1/2,
10, 13 and 15 etc) and the cooling method used: -A for air-cooled, -W for water-cooled, and –
R for remote-air cooled.
2-2 General Description
Our portable chillers are reliable, accurate, and easy to use process cooling units. They are
available in air-, water-, and remote air-cooled designs in a range of sizes from 5 to 15 tons.
All are self-contained, fully portable and shipped ready to use. (Remote air-cooled chillers
require field installation by qualified technicians.)
Standard range of operation is 20ºF to 80ºF (-7ºC to 30ºC) for applications using a
water/glycol mix and 45ºF to 80ºF (7º to 30ºC) for water only applications.
A factory installed crankcase pressure regulating valve option is available for processes
requiring a leaving water temperature over 80ºF (30ºC).
Chilled Water Circuit
Cooling water “To Process” and “From Process” connections are made at the female NPT
couplings provided outside the unit. Warm coolant (water and glycol mixture) returns from
the process and goes into the reservoir tank. The coolant is then pumped through the
evaporator where it is cooled. The coolant flows to the process and returns to repeat the cycle.
A (manual) pressure actuated process water bypass valve located between the supply line and
reservoir tank (single pump models only) allows minimal flow through the unit during the
intermittent fluctuating flow conditions. It is not intended to provide continuous full bypass
flow.
This minimal flow allows the temperature sensor to signal the controller to shut down the
compressor because of the drop in process water temperature. Typically the flow switch shuts
down the chiller in this low flow condition. This valve allows enough flow for the chiller to
function when the flow is shut off to process.
Refrigeration Circuit
Air-, water-, and remote air-cooled refrigerant condensing differ only in the way the
compressed gas is condensed to a liquid.
Liquid refrigerant from the condenser heat exchanger flowing in the liquid line passes
through a shut-off valve into a filter/dryer that removes moisture and other contaminants. A
refrigerant sight glass is provided. The refrigerant then passes through the thermal expansion
valve, which allows the refrigerant to expand (boil off) and cool (remove the heat from) the
fluid inside of the evaporator. The refrigerant gas flows through the suction line back into the
compressor.
GP Series Portable Chillers Chapter 2: Functional Description 7 of 44
The refrigerant is compressed in the compressor and flows through the discharge line as a gas
to the condenser. There it gives up its heat as it condenses to a liquid in the condenser.
An electronic hot gas bypass valve is used to control cooling capacity during intermittent or
partial load conditions. This feature contributes substantially to chiller longevity by
eliminating excessive cycling of the compressor and providing close temperature control.
2-3 Standard Features
Mechanical Features
Compressor. Hermetic scroll compressors.
Evaporator. Stainless steel copper brazed plate evaporators.
Air-Cooled Condenser. Aluminum fin/ tube with washable filters, package unit only (option
on remotes).
Water-Cooled Condenser. Tube-in-tube condensers. All come with electronic cooling
water regulating valves for cooling tower water or city water.
Remote Air-Cooled Condenser. Aluminum fin/tube with low ambient control down to –
20ºF (-29ºC) via a variable-speed primary fan.
Reservoir. 5 hp and 7.5 hp models use a 20 gallon polyethylene tank. 10 hp and 15 hp
models use a 40 gallon polyethylene tank.
Piping. Non-ferrous piping
Pump. TEFC motors (Optional 10 HP is ODP only)—horizontally mounted stamped
stainless steel construction.
Other Mechanical Features
• Low process water thermal flow switch
• NEMA-rated fan motor(s) on air-cooled models
• Galvanized structural steel frame, painted cabinetry, with 4” (locking) swivel casters
• Internal process water bypass valve for system protection only
• Fully insulated refrigeration and process water piping
• 20 mesh Y strainer on process water piping into the evaporator
• Tank level indication
• Pump pressure indication
Electrical Features
• Fully accessible NEMA 12-style electrical control enclosure
• Single-point power and ground connection
• Non-fused disconnect switch, lockable
• Branch circuit fusing
• 208-230/3/60, 460/3/60, 575/3/60 volt; 400/3/50 volt
GP Series Portable Chillers Chapter 2: Functional Description 8 of 44
Refrigeration Features
• HFC-410a refrigerant
• Electronic hot gas bypass capacity control
• High refrigerant pressure cutout switches
• Suction and discharge pressure transducers.
• High pressure spring actuated relief valve
• Multiple refrigeration access ports
• Liquid line shut-off ball valves
• Filter-dryer
• Sight glass
• Externally equalized thermal expansion valve
• Liquid line solenoid
• Compressor crankcase heater
Controller Features
• Off-the-shelf microprocessor-based PID auto-tuning controller with To Process, From
Process and Set Point readout
• Time delay for proof of water flow/pressure (models w/pump only)
• Low refrigerant pressure time delay for low ambient start-up on remote air-cooled and
air-cooled chillers with the variable-speed fan option.
• 4 line x 20 character display with status, alarm, and service screens
Other Features
• One year labor warranty and one year compressor warranty
• Two year parts warranty
• Two year limited controller warranty
2-4 Safety Devices and Interlocks
Caution! Protect the system from freezing with glycol 20ºF below the leaving water
temperature set point. Condensation may form inside the pump tank and dilute
the mixture, therefore the freezing point should be verified periodically. See
Figure 6 on page 18 for the correct mixture.
Crankcase Heater
5 hp through 15 hp portable chillers have a crankcase heater. It is wired through the control
transformer that operates continuously whenever power is applied to the chiller.
Caution! Energize the crankcase heater for at least 24 hours before initial startup to
drive dissolved refrigerant from the compressor oil. Failure to do so will
damage the compressor.
GP Series Portable Chillers Chapter 2: Functional Description 9 of 44
High Pressure Cutout
This electro-mechanical cutout device opens the compressor control circuit if the refrigeration
system compressor discharge pressure exceeds 575 psi..
Note: The high-pressure cutout is a manual reset device typically mounted on the
compressor discharge line inside the mechanical cabinet. Call a refrigeration
service technician to analyze the problem and reset the control.
Low Pressure Cutout (no switch but done through the transducer)
This electro-mechanical cutout device opens the compressor control circuit if refrigeration
system compressor suction pressure drops below 15 psi. It automatically resets when
refrigerant suction pressure reaches 30 psi.
Note: The low pressure cutout is an automatic reset device typically mounted on the
compressor suction line inside the mechanical cabinet. Call a refrigeration
service technician to analyze the problem and reset the control.
Flow Switch
The thermal dispersion flow switch cutout device, mounted in the process piping, shuts down
the chiller if it senses that the water/glycol flow rate through the evaporator has dropped
below an acceptable level. The flow switch opens the control circuit and shuts down the
pumps and the chiller.
Remote Start/Stop Interlock
An additional contact is provided to allow the remote starting or stopping of the chiller. To
use this feature, remove the jumper between terminals X1 and 1, and supply a switch or dry
contact interlock connected in series between these two terminals. Refer to the schematic
inside the control enclosure door.
2-5 Optional Features
Options marked with “*” indicate options that can be factory installed or retrofitted in the
field.
Automatic Water Make-Up*. Not available on chillers less reservoir tank. Includes an
electric water solenoid valve, a level sensing pressure switch mounted in the reservoir tank,
and the necessary internal piping to connect the chiller to a make-up water source. See
Appendix for typical piping diagrams.
Caution! Customer piping must provide backflow protection and venting of tank to
atmosphere to prevent over-pressurization of the reservoir tank (not needed for
open tank). See Error! Reference source not found. on page Error! Bookmark
not defined..
Process Water Sidestream Filter*. Not available on chillers less pump and reservoir tank.
Includes a 50 micron filter, flow meter, ball valve for throttling water flow, and the necessary
piping to provide constant filtering of the process water at about one gallon per minute (1
gpm/3.8lpm).
General Fault Indicator Audible/Visual Alarm*. Includes a 100 dB audible alarm horn/
visual alarm strobe and silence button with provisions for customer wiring indication
GP Series Portable Chillers Chapter 2: Functional Description 10 of 44
interlock. The alarm signals anytime that a fault is recognized during the operation of the
chiller.
Communications Options. RS-485 serial Modbus communications.
High Pressure Fans. Provides for an additional 1.0”WC (250 Pa) of static pressure on fan
discharge. High-pressure fans are necessary and must be included in chiller installations
where exiting air exhausts through ductwork.
They can be retrofitted without sheet metal modification, but will require changing out fan
blades, and in some cases, fan motors and electrical components.
Variable Speed Fan. Reduces the speed of the fan based on entering air temperature and
system load, allowing the chiller to operate in ambient temperatures below 60ºF (15.5ºC).
This option will also reduce fan noise in ambient temperatures below 95ºF (35ºC).
Stainless Steel Reservoir. 5 hp to 15 hp models only. Manufactured from 304 stainless steel.
Mounting Features.
• Mounting rails with feet
Optional Operating Voltages. 208-230/3/60, 575/3/60, and 400/3/50 volt available
UL Labeled Electrical Subpanel. Provides for the subpanel to be listed with Underwriters
Laboratory, with UL-related benefits and features.
Optional Pumps. Pump options are available for greater pressure and flow rates. A
recirculation pump is required whenever process water flow is less than 1.2 gpm per ton or
greater than 4.8 gpm per ton. See Figure 1 on page 12 for optional pump amperages.
NEMA 4 Electrical Enclosure. Provides for NEMA 4-level electrical enclosure protection.
GP Series Portable Chillers Chapter 2: Functional Description 11 of 44
Figure 1: Optional Pump Amperages
Voltage Construction HP Full Load Amps
460/3/60 SS 1 1.7
1.5 2.3
2 4.0
3 4.2
5 8.2
10 12.0
GP Series Portable Chillers Chapter 2: Functional Description 12 of 44
Chapter 3: Inst allation
3-1 Uncrating
All models are are shipped mounted on a skid, enclosed in a plastic wrapper, and open-crated
on all four sides and top.
1. Pry the crating away from the skid.
2. Use a pry bar to remove the blocks securing the unit to the skid.
3. Lift unit from sides, inserting forklift under the base. The forks must be equidistant
from the centerline of the unit and the unit must be balanced on the forks. Lift slowly
and only high enough to clear the skid. Use a pry bar if necessary to carefully remove
the skid from the unit.
4. Lower slowly. The unit should land on its casters or rails and can then be moved into
position.
5. Retain the crating material for reshipping the chiller in case hidden shipping damage
is found.
3-2 Electrical Connections
Supply electricity of the voltage, phase, and cycle listed on the serial tag. Total running amps
are also found in the specification tables on pages in the Appendix.
Bring properly sized power leads and ground from a fused disconnect (installed by your
electrician) to the unit. Use dual-element fuses in the disconnect switch, sized according to
the National Electrical Code recommendations. Note the outline drawings for egress into the
cabinet. Make sure all electrical connections are tight.
Refer to your local electrical requirements for proper feeder conductor and
supply disconnecting sizing. For instance, in the United States refer to
National Electric Code (NEC) Article 430-24 through 430-26, Table
Important!
310.15(B)(2)(a)
GP Series Portable Chillers Chapter 3: Installation 13 of 44
3-3 Process Water Connections
All of our portable chillers have two chilled water connections. The chilled water supply,
labeled “To Process” is the outlet for the chilled water leading to the process being cooled.
The chilled water return, labeled “From Process” is the inlet leading from the process back
into the chiller to be cooled and re-circulated.
All external chilled water connections should be run full size to the process. Flow and
pressure information is available in the Appendix. The largest possible openings and
passages should be provided for the flow of chilled water through platens, dies, molds, or
other pieces of equipment.
Note: Be sure to reduce external pressure drop as much as possible by generously
sizing piping and tooling water passageways.
3-4 Bypass Valve Considerations
Our portable chillers have an internal manual bypass valve. If the flow is stopped to the
process while the chiller is running, the factory-set bypass valve allows a small amount of
water to flow through the chiller. This action allows the chiller to keep functioning while the
flow is stopped to process. The bypass valve is not intended to provide continuous full
bypass flow.
Caution! Do not attempt to adjust or otherwise tamper with the internal bypass. Your
warranty will be voided.
3-5 Galvanic Corrosion Considerations
The materials used in the water circuit piping of these chillers are non-ferrous and react
electro-chemically with ferrous metallic materials. Some water has dissolved minerals that
greatly accelerate the reaction between dissimilar metals.
PVC or non-ferrous piping is recommended to reduce galvanic action. If iron piping must be
used, use dielectric unions at the chiller.
3-6 Water Treatment Considerations
Water treatment is an integral part of the system. In some locations, water may cause large
deposits of scale, erosion, algae, and/or corrosion.
Note: The use of poor quality water may result in inefficient operation, heat
exchanger damage, and pump seal damage. Consult a qualified water
treatment specialist to determine whether treatment is needed.
We offer a complete line of water treatment equipment. Contact your sales representative for
water testing and treatment options.
GP Series Portable Chillers Chapter 3: Installation 14 of 44
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